Materials and methods for constructing a block wall

ABSTRACT

A construction block for use with other like construction blocks to build a retaining wall. The block has substantially parallel top and bottom surfaces, and two substantially parallel sides. The front of the block is “bullet shaped,” with a front nose surface being substantially perpendicular to the top, bottom, and side surfaces. Angled front sides join the nose surface to the sides, forming a 45° angle with the front and side surfaces. The rear portion of the block is generally a mirror of the front portion, with a rear surface that is substantially parallel to the front nose surface and substantially perpendicular to the top, bottom, and side surfaces. Angled rear “tail” surfaces connect the side surfaces to the rear surface at a 45° angle. The edges where the top surface joins the side and front surfaces may be beveled. At least one hole is located in the front portion of the block, passing vertically through the block from the top surface through the bottom surface. At least one hole may additionally be located in the rear portion of the block. The rear hole may be open to the rear rather than being fully closed. Multiple front holes and multiple rear holes may be provided.

This application claims priority from applicant's copending applicationSer. No. 60/444,067, which is incorporated herein by reference in itsentirety.

FIELD OF THE INVENTION

The present invention relates generally to block wall systems, and moreparticularly to a construction block for use interlocked with other likeconstruction blocks to build a wall. Methods of constructing walls withthe inventive construction block are also disclosed.

BACKGROUND OF THE INVENTION

Retaining walls have long been constructed from a variety of commonbuilding elements such as railroad ties, timber, bricks and stones. Inrecent years, construction blocks have been developed which arespecifically adapted for the construction of retaining walls. The designof these construction blocks is often intricate and far removed from thesimple concrete rectangular shaped blocks long used in the constructionof warehouses, basements and the like. For example, current retainingwall construction blocks do not require mortar between the blocks,instead employing various interlocking arrangements and often times usedin conjunction with the adjacent land to provide a decorative, yetstrong retaining wall.

The degree of skill required to build a retaining wall depends on theparticular design of the block. For example, when building a retainingwall it is desirable for the stacked blocks to be set back from oneanother, thereby resulting in a canted, rather than vertical, wall whichfully supports the adjacent earthen structure. The most simple of blocksrequire the skill of an artisan to provide the proper setback whenbuilding the retaining wall. Other blocks include frontal ridges or atongue-in-groove construction for locating like blocks a fixed distanceback from one another to provide a predetermined amount of setback.Still other blocks include holes extending through the block so thatwhen stacked upon other like blocks, anchoring pins may be insertedthrough the aligned holes to result in a strengthened wall. See, forexample, U.S. Pat. No. 4,996,813.

There is always a need for an improved retaining wall block design. Forexample it would be advantageous if a plurality of blocks could be setin place before they are attached to a foundation. However, currentconcrete molded blocks and methods for their use require that verticalenforcing elements be installed in the foundation before the blocks arestacked. This method is laborious since each block must be lifted overthe vertical rods connecting the block to the courses below. It alsoslows construction in that care must be taken to ensure that thevertical enforcing elements are properly aligned within the foundationbefore the blocks can be installed to form the finished wall.

Rather than requiring the need for a plumb bond or level to ensureproper alignment of each block it would be advantageous to supply asimple means for properly aligning each block without the need forresort to these tools as each block is placed. Retaining wallsconstructed using currently available molded concrete blocks require thetime consuming and skill intensive alignment of each member to ensurethat the blocks are properly aligned to construct a robust and visuallypleasing finished wall. Therefore, it would also be desirable if theblocks were constructed such that a wall could be constructed of theseblocks using simpler more efficient methods for aligning the blocks.

Retaining walls are often constructed in a setback (canted) manner suchthat successively higher courses are set back away from the face of thecourse beneath it. This may be done for structural or aesthetic reasons.Current molded concrete blocks and methods for using these to buildcanted walls requires considerable skill and time to ensure that thefinished wall is structurally sound and presents a visually pleasinguniform face. Therefore, it would be desirable for the blocks used tobuild canted walls to be complete with a simple means of ensuring theirattachment to adjacent courses and to be readily and uniformly offset bydesign, without recourse to time-consuming and skill intensive labor.

It is often advantageous and even necessary that walls constructed atleast in part by concrete molded blocks can be anchored to adjacentbodies such as the earth behind the wall or a concrete wall behind theblock wall. This is especially important with retaining walls wherein atleast one purpose for the wall is to hold back earth abutting the backof the retaining wall. With most concrete molded blocks used toconstruct retaining walls, the courses may be ‘tied’ to the earth behindthe wall by wire or other means placed between selected courses ofblock. These earth ties are generally held in the wall solely byfriction between the tie and the courses of block it is engaged with onthe wall side. This system relies on the weight of the courses of blockabove the tied layer to ensure that the ties do not slip out frombetween the block. Ties inserted further up the height of a given wallwill have fewer courses of overlying block holding them in place. Thefurther up the wall such ties are used the more vulnerable the tie willbe to failure. That is, earth ties currently used with molded concreteblock walls, become less reliable at precisely the location in the wallwhere the ties may be most necessary. Therefore, it would beadvantageous if a molded concrete block were made and used such thatearth ties could be more effectively attached to any course of blockswith an increase in security over existing blocks and molded concretewall systems.

It may be advantageous to secure a retaining wall to a portion of earthsituated beyond the natural slope of the earth held back by the wall.The natural slope of a given material is at least partially determinedby the coefficient of friction of the material comprising the material.Retaining walls often used to hold earth in place located stable slopeof the earth and the back of the wall. Currently used molded concreteblocks and retaining walls constructed using these blocks provide noready means for securing the wall to sections of earth far enough behindthe wall to ensure the integrity of the wall. Therefore it wouldadvantageous is a molded block and methods for constructing wall ofthese blocks provided a means of anchoring at least a portion of such awall to sections of the earth far enough behind the back of the wall toensure the wall's structural integrity.

Current molded concrete blocks, and methods for using these blocks toconstruct retaining walls, are too labor intensive, increasing the costof such structures. Currently available molded concrete block retainingwalls are often not robust enough to adequately resist the lateralforces imposed on the walls. This is especially true over a long periodof time and upon exposure of the wall to additional forces such as,wind, rain, snow, freeze-thaw cycles, shaking, and additional loadsimposed by for example an adjacent road or other structure, to name afew.

Some retaining wall systems employ three or more different block designsin the construction of a retaining wall. In U.S. Pat. No. 4,996,813, acommon sound block was disclosed which could be used for both thestraight sections and the corner sections of a retaining wall. Yet othercommon block designs are desirable as well. For example, it is desirableto have a common construction block which both interlocks with andadjusts relative to adjacent like blocks to form both straight andsetback walls.

With these thoughts in mind, an improved retaining wall block is needed.The block should be of a common design and should interlock with otherlike construction blocks to form a retaining wall. Preferably, the blockshould be easily produced using standard concrete molding techniques andmasonry machinery. Ideally, the block would be abutted to adjacent likeblocks to form both straight and setback walls. Such blocks should bereadily aligned, both within and between courses. These blocks should beeasily attached to the earth or foundation beneath the bottom mostcourse of the wall. These blocks should be suitable for the constructionof reinforced walls adequately anchored to other blocks with the walland to structures adjacent to the wall such as the earth or other walls,such as concrete walls, adjacent to the molded block wall.

SUMMARY OF THE INVENTION

Briefly describing one embodiment of the present invention, there isprovided a construction block for use with other like constructionblocks to build a retaining wall. The block has substantially paralleltop and bottom surfaces, and two substantially parallel sides, with thesides being substantially perpendicular to the top and bottom surfaces.The front of the block is “bullet shaped,” with a front nose surfacebeing substantially perpendicular to the top, bottom, and side surfaces.Angled front sides join the nose surface to the sides, forming a 45°angle with the front and side surfaces. The rear portion of the block isgenerally a mirror of the front portion, with a rear surface that issubstantially parallel to the front nose surface and substantiallyperpendicular to the top, bottom, and side surfaces. Angled rear “tail”surfaces connect the side surfaces to the rear surface at a 45° angle.The edges where the top surface joins the side and front surfaces may bebeveled.

At least one hole is located in the front portion of the block, passingvertically through the block from the top surface through the bottomsurface. Preferably, at least one hole is additionally located in therear portion of the block. The rear hole may be open to the rear ratherthan being fully closed. Multiple front holes and multiple rear holesmay be provided.

In one aspect of the present invention the block has one or more groovesin one or more of its surfaces to facilitate anchoring the block. Inanother embodiment the block has one or more cut out portions tofacilitate anchoring the block.

Walls, including retaining walls, may be constructed from the blocks byplacing multiple blocks front-to-end or side-to-side. The fact that therear surfaces correspond in shape (i.e., mirror) to the front surface ofthe block facilitates the front-to-end placement. With the disclosedshape the front portion of one block fits snugly into the rear portionof the adjacent block. Courses of block may be laid, one upon the other,to construct a wall. Successive courses may be laid with the blocksfacing the same direction as the blocks in the course immediately belowit, or they may be laid with the blocks facing in the opposite directionas the blocks in the course immediately below it. With either method,the blocks may be arranged such that the hole(s) of each block line upwith the hole(s) of the block immediately below it. When the blocks areso aligned, successive courses may be tied together by runningstabilizing members through the holes and securing the stabilizingmembers to the uppermost and lowermost blocks (or to something above theuppermost block or below the lowermost block). The courses may bealigned by aligning the holes in the blocks, such as, for example, witha rigid tool or vertical-stabilizing element extending through aplurality of courses.

Canted, or “setback” walls may be constructed from these blocks bystacking a succeeding course such that it covers only a portion of thecourse below it. When the blocks have a multiplicity of holes arrangedeither front-to-back or side-to-side, the holes may be aligned such thatsuccessive courses can be tied together through their holes. When threeholes are provided in each block, a course may thus be tied to twocourses above the block, and two courses below the block. This makes fora particularly strong wall.

The optional grooves in one surface of the block, such as, for example,in the top surface, may be used to hold a stabilizing element, such as ahorizontal stabilizing element. When the block has beveled edges asimilar result may be obtained using the beveled surface.

In one embodiment of the invention, vertical stabilizers are affixed tothe earth or foundation beneath the first course of block comprising thewall. Vertical stabilizers may be rigid members such as metal rods andthe like, or flexible member such as metal or composite cables. Thesevertical-stabilizers may extend between a plurality of courses includingfrom the foundation to the top most course of the wall. They may begrouted into place. Vertical-stabilizers may also be connected tohorizontal stabilizers such as those running between blocks with a givencourse and/or to ties connecting the wall to adjacent structures such asthe earth or other walls.

In one embodiment of the present invention, vertical-stabilizers areadded to the completed walls or completed portions of wall aftersucceeding courses of blocks are already layered upon one another. Aplate longer than the width of an oblong hole in a wall block butshorter than the long axis of the oblong hole is affixed to a rod. Therod is inserted through the oblong holes in at least one course ofblock, and is then turned such that the long axis of the plate engagesthe narrow section of the lower surface of a lower course of block. Onceengaged the rod may be tensioned by placing an upward force on the rodcausing the plate on the rod to engage the bottom surface of the lowercourse of block. This method is especially useful when it is desirableto increase the integrity of the wall by connecting the coursesvertically.

In another embodiment of the invention, rods with end plates, or soilscrews are affixed to the one end of a rod. The rods are then insertedthrough the oblong holes in at least one course of block and turned intothe earth beneath the lowest course of block comprising the wall. Oncesecurely engaged to the earth the upper portions of these rods may betensioned against an upper surface of a block. This method is especiallyuseful when there is no concrete foundation beneath the first course ofblock and it is desirable to install a plurality of courses beforesecuring these courses to one another by use of a vertical-stabilizer.

One embodiment of the invention provides molds for making concreteblocks with variable surface characteristics. Molds are made withremovable elements that allow a mold with the same over-all outsideshape to produce blocks with different surfaces. For example the upperportion of the mold can be fitted with inserts that produce a block witha chamfered edge. In another embodiment a mold for producing two moldedconcrete blocks in the same mold can be fitted with a triangle shapedinsert that produces a pair of blocks that when split have a total ofsix smooth front end faces.

In another embodiment of the invention the multi-block mold body is notfitted with the triangle adapter. The mold configured in this mannerwill produce two blocks that have a side running the entire length ofthe block and a shorter parallel side joining the front most face andshort side. Such blocks may be split to form blocks with two forwardtransitional faces. Blocks produced by spitting-out the second facejoining the forward face and side the split-out side face will have atextured joining face.

Further objects and advantages of the preferred embodiments will becomeapparent from the following drawings and written description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A, 1B and 1C illustrate a top view, a front perspective view, anda rear perspective view of one block made in accordance with oneembodiment of the invention.

FIG. 2A illustrates a top view of two blocks abutting one another inaccordance with one embodiment of the invention.

FIG. 2B illustrates a top view of three blocks abutting one another inaccordance with another embodiment of the invention.

FIG. 3 illustrates perspective views of blocks made in accordance withthe invention in different courses overlying one another.

FIG. 4 illustrates a perspective view of multiple courses of a wall,showing a vertical reinforcement element.

FIG. 5 illustrates a side view of wall constructed from blocks made inaccordance with the invention showing two forms of verticalreinforcement.

FIG. 6 illustrates a perspective view a block attached to a reinforcingelement.

FIGS. 7A, 7B, and 7C illustrates a method for providing a verticalstabilizing element through multiple courses of blocks.

FIG. 8 illustrates a vertical stabilizing element made of multiple,coupled threaded rods.

FIG. 9 illustrates a block of the present invention being anchored to afoundation.

FIG. 10 illustrates a top view of multiple blocks used to make a FIG. 11illustrates a top view of two blocks forming a bend in accordance withone embodiment of the invention.

FIG. 12 illustrates a top view of two blocks forming a 90° corner inaccordance with one embodiment of the invention.

FIG. 13 illustrates blocks in adjacent courses that face in oppositedirections yet form a 45° bend in a wall.

FIG. 14 illustrates a top view of a block having multiple holes in thefront half of the block.

FIG. 15 illustrates a sectional view of a canted wall showing thepresence of vertical reinforcing elements within the wall.

FIG. 16 illustrates a perspective view of a block of the presentinvention, showing the presence of a channel for positioning a supportmember.

FIG. 17 illustrates blocks using lateral supports made in accordancewith one embodiment of the invention.

FIG. 18 illustrates a block having multiple holes in the front half ofthe block, and using lateral supports to stabilize the block.

FIG. 19 illustrates a top view of blocks with a front to back groovemade in accordance with one embodiment of the invention.

FIG. 20 illustrates a block wall engaged with a grid to stabilize theelement.

FIG. 21 illustrates a block having a cut out in the side of the block.

FIG. 22 illustrates angle irons that may be used with the block of FIG.21.

FIGS. 23-27 illustrate alternative embodiments of certain aspects of thepresent invention.

FIG. 28 illustrates alternative embodiments for positioning multipleblocks to form columns, parapets, or turns in a wall.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of promoting an understanding of the principles of theinvention, reference will now be made to preferred embodiments, andspecific language will be used to describe the same. It willnevertheless be understood that no limitation of the scope of theinvention is thereby intended, such alterations, and furthermodifications in the illustrated device, and such further applicationsof the principles of the invention as illustrated therein beingcontemplated as would normally occur to one skilled in the are to whichthe invention relates.

Referring now to the drawings, FIG. 1 shows a construction blockaccording to one embodiment of the present invention. Construction block10 has a substantially planar top surface 11 and a substantially planarbottom surface 13 that is parallel to top surface 11. The block has twoside surfaces 12 a and 12 b that are substantially parallel to oneanother and substantially perpendicular to the top and bottom surfaces.

The front of the block has a nose portion extending beyond the sidesurfaces and ending in a front surface 14. Front angle surfaces 16 helpdefine the nose by joining side surfaces 12 a and 12 b to front surface14, preferably at a 45° angle.

The back of the block is shaped so as to accept the front of acorresponding block. Accordingly, the back of the block includes rearsurface 15, which is connected to side surfaces 12 a and 12 b by rearangle surfaces 17. One or more of the edges, and particularly the edgeswhere the top surface abuts a side or nose surface, may be beveled orchamfered, as shown by edges 12 c, 14 c, and 16 c.

There is at least one hole through the block, such as front hole 18shown in FIGS. 1A-1C. In one preferred embodiment, there are multipleholes, which may be arranged in substantially any manner. Preferably,one of the holes is located at the rear of the block, intersecting rearsurface 15. Such a hole 19 may be open to the back, as shown in FIG. 1.Preferably the holes extend completely through the block, from the topsurface to the bottom surface. In the most preferred embodiments one ormore of the holes is oblong as shown in FIGS. 1A-1C.

The blocks may be sized so as to be handled by an individual whenconstructing a wall, such as the size generally associated with commonconcrete blocks, although larger or smaller blocks may also beconstructed. In one preferred embodiment the block is about 24 incheslong, 18 inches wide, and 8 inches high. In another preferred embodimentthe block is about 18 inches long, 12 inches wide, and 6 inches high.

The blocks may be made from any material appropriate for use in aconstruction project. Preferred blocks are made of concrete.

The blocks may be assembled together to form a wall or otherconstruction project by placing multiple blocks end-to-end orside-to-side. For example, FIG. 2A shows two blocks abutted in afront-to-back orientation in accordance with in one embodiment of theinvention. Blocks 20 a and 20 b are positioned front to rear to form apair of abutted blocks. Blocks 20 a and 20 b are positioned such thatthe front surface 24 b of block 20 b abuts the rear surface 25 a ofblock 20 a. The front angled surfaces 26 b of block 20 b abut the rearangled surfaces 27 a of block 20 a. In one preferred embodiment of theinvention the nose 24 b of block 20 b abutting the rear 25 a of block 20a forms a semi-oblong space 29 extending from the top of the pair to thebottom of the pair. A plurality of blocks may be positioned nose to endsuch as the blocks in FIG. 2A to form courses of any desired length.

Alternatively, multiple blocks 20 a, 20 b, 20 c, etc., may be laidside-to-side as shown in FIG. 2B to form a course of a wall.

Regardless of whether courses of blocks are formed by placing blocksfront-to-end or side-to-side, it is to be appreciated that courses ofblocks can be layered to build a wall or other construction project. Forexample, FIG. 3 shows one embodiment of the invention wherein courses ofblocks are layered upon one another to form a wall. Any number ofcourses of blocks can be layered upon one another. In one embodiment thefront to back alignment of blocks in adjacent courses alternates fromcourse to course. In another embodiment of the invention the front toback alignment of blocks within a course is the same in all courses. Itis also within the scope of the invention to use both courseorientations within the same wall.

In one preferred embodiment of the invention, holes 18 and/or 19 in atleast adjacent courses are aligned as shown in FIG. 3. When the holesare aligned, a tool sized and shaped to fit into the hole may be driventhrough aligned holes in consecutive adjacent courses forcing blockswith a given course and between adjacent courses into a snug and planarfit.

Vertical, horizontal, and lateral stability are always of concern inwall construction, and especially in the construction of retainingwalls. This is particularly true in mortarless wall construction.Currently available mortarless wall systems use simple friction betweencourses to stabilize walls or on a system of course to course lips andgrooves to reduce vertical or lateral shifting between courses within awall.

One technique sometimes used the construction of mortorless retainingwall is to insert vertical rods in the foundation beneath the lowestcourse of block in a wall. Blocks with some form of void in the blockbody are then lifted over the top of the fixed vertical rods and set inplace. The technique is both skill and labor intensive. The rods must beproperly spaced when the foundation is poured to correspond to voids inthe construction blocks. And once course building begins, blocks must belifted over the top of each vertical rod greatly increasing the laborand expense of constructing wall using this technique. Clearly then,there is a need for a system of retaining wall construction that is lesslabor and skill intensive and creates in finished wall with greaterstability than the mortarless systems currently in use.

The present invention provides molded blocks that have features that aidin securing courses made with these blocks to other correspondingcourses, resulting in finished walls with excellent vertical stability.For example, FIG. 4 shows overlying courses of blocks that may besecured to one another in accordance with one embodiment of theinvention. Vertical supporting elements 40 are inserted through thealigned oblong spaces 48 and/or 49 running through courses of blocks toadd strength and stability to structures formed from the blocks. Once inplace the vertical reinforcing elements can be joined to the blocks byadding grout to the oblong spaces, thus further securing reinforcingelement 40.

In one aspect of the invention a plurality of blocks are positioned inlayered courses of blocks and joined together with vertical reinforcingelements 50 to form walls as illustrated in FIG. 5. The verticalreinforcing elements 50 may extend through all the courses of block in awall, through select courses of block in the wall as shown byreinforcing elements 55, or any combination thereof.

Those skilled in the art will recognize that the installation ofvirtually any vertical stabilizers between any number of courses withina wall will add stability to the wall. It is within the scope of theinvention to use vertical stabilizers/reinforcing elements to join anyset of adjacent courses or any plurality of layered courses made withthe inventive blocks, and to insert these elements wherever and wheneverit is advantageous to do so.

In another embodiment of the invention, the vertical stabilizers may befixed to a concrete foundation beneath the lowest course of blocks, orto earth or stone beneath the first course of blocks. In suchembodiments the vertical reinforcing elements may extend up through onlypart of the first course, through all of the courses in the wall, orthrough any intermediate number of courses in the wall.

Vertical reinforcing elements also referred to herein as verticalstabilizers for the practice of this invention includes metal orcomposite rods, bars, straps, cables, and the like. Vertical stabilizerssuitable for the practice of this invention also include, sand, gravel,cement, glue, grout, and the like that can be set into oblong spaces inadjacent courses. While the invention is illustrated primarily usingblocks 10, it is also within the scope of the invention to use any blockwith oblong spaces through adjacent courses and the same correspondingfront to back shape as block 10.

Referring now to FIG. 6, a construction block may be provided with adevice for attaching a vertical reinforcing element made in accordancewith one embodiment of the invention. Accordingly, construction block 60includes a securing device 61 deigned to attach to avertical-reinforcing element 62. In the illustrated embodiment securingdevice 61 comprises a plate 64 attached on one side to block 60 and theother side to threaded nut 66. The vertical element 62 is a threaded rodthat is joined to block 60 by turning the rod 62 into nut 66. The plate64 may be joined to the block by any suitable means known in the art forjoining blocks and supports such as gluing using for example epoxy glue,nailing, riveting, screwing, or casting the plate as part of the moldedblock.

In one preferred embodiment of the invention, block 60 is used as afirst, lowermost course. The course of blocks 60 are preferably set inor on a concrete foundation, or in or on a layer of prepared earth orstone. Once in place, corresponding courses of block are layered aboveblocks 60. After any number of courses are installed, a verticalstabilizer rod 62 may be inserted through the oblong spaces in overlyingcourses and engaged to device 66. This allows the wall to be constructedwithout having to lift succeeding courses of block over an upstandingvertical stabilizer. As may be appreciated though, vertical-reinforcingdevice 62 may be attached to block 60 before overlying courses areconstructed.

In another embodiment of the invention the locking device of block 60 isa loop and the verticals support device is cable or strap with a hookthat is inserted through oblong spaces in the courses overlying the loopand attached to the loop. Once the hook on the cable is engaged to theloop the cable can be tensioned from above, drawing the interveningcourses closer together, thereby strengthening the wall.

Referring now to FIGS. 7A, 7B and 7C, a device for securing a verticalreinforcing element may comprise an oblong plate at one end of thereinforcing element. In that embodiment plate 71 for engaging the bottomsurface of a block 70 is affixed to a vertical-stabilizer 72. The plate71 is sized and shaped so that it can be inserted through the oblongspaces 78 in successive courses of blocks. Because an oblong hole 78 islonger along one axis than the other, plate 71 can be sized and shapedsuch that when the plate is inserted through an oblong space in a courseof blocks and turned (preferably by about 90°) it will engage the lowerface of block 70. Thus, vertical-reinforcing element 72 can be tensionedto compress intervening courses of blocks. Compressed courses are morestable then non-compressed courses and vertical compression of coursecan also be used to secure horizontal and lateral stabilizing elementsto create a wall with an integrated stabilizing system.

Referring now to FIG. 8, a modular vertical stabilizer may be providedaccording to another embodiment of the present invention. In such anembodiment, a vertical reinforcing element comprises bars 80, barcouplers/connectors 88, and a tensioning mechanism. Bars 80 andconnectors 88 are threaded into one another to create continuousvertical stabilizer of any advantageous length. The reinforcing elementmay also include threaded nuts 82 for securing and positioning couplers88. In some embodiments an anchor plate 86 may also be included. Anchorplate 86 may be secured with anchor nut 84 and/or top nut 85. Thestabilizer can be tensioned turning the anchor nut 84 against anchorplate 86.

Walls built with these vertical-reinforcing elements can be stabilizedin sections as the wall is being built. This reduces the risk that awall will topple while it is under construction. It also provides ameans of adding vertical reinforcing element to a wall without the needfor lifting blocks in succeeding courses over vertical rods extendingupward from lower courses.

Referring now to FIG. 9, a stabilizing element 92 may extend through thelowermost block in a course of blocks and may be anchored into theground/foundation 96. The oblong spaces in the blocks may be used as atemplate to drill holes in the foundation 96 for the insertion ofvertical-stabilizers into the foundation. Vertical reinforcing elements92 extending up to any advantageous height may be inserted into thefoundation.

In still another preferred embodiment of the invention, after holes 94are drilled in the foundation 96 a cartridge of epoxy is left in eachhole. Succeeding courses of blocks are then layered over the foundation,taking care to align oblong spaces in each course with correspondingspaces in adjacent courses and the holes 94 drilled in the foundation.Once a number of aligned courses are in place, a vertical stabilizer 92is inserted through spaces 98 in the blocks and is “drilled” down intofoundation holes 94, rupturing the cartridge of epoxy and activating theepoxy to effectively glue vertical-stabilizer 92 to foundation 96. Therest of the vertical-stabilizer 90 is joined to blocks in the wall bygrout in spaces 98. This method allows courses to be joined to oneanother and eliminates the need to lift blocks in new courses oververtical support elements that are protruding upwards from lowercourses. It also frees the oblong spaces in each course to be used toalign the blocks within the courses.

It is well known in the art that undulating walls and walls withinternal and external corners are more stable then simple straight wallsof equivalent design. Accordingly, the blocks of the present inventionmay be used to build undulating walls and/or to build columns orpilasters into walls, thus enhancing wall strength and stability. Inaddition to adding strength and stability to walls, undulations may beused to conceal adjacent structures such as concrete pilasters orcolumns, or for essentially aesthetic purposes.

Referring now to FIG. 10, walls having 45-degree turns/corners can bemade in accordance with one embodiment of the invention. In particular,blocks 100 a, 100 b, and 100 c may be placed such that front angledsurface 106 b abuts rear surface 105 a of the block ahead of it, whilefront surface 104 b abuts rear angled surface 107 a. This allows block100 b to be placed at a 45° angle with respect to block 100 a. To returnthe wall to its original orientation, block 100 c may be placed suchthat front angled surface 106 c abuts rear surface 105 b of the blockahead of it, while front surface 104 c abuts rear angled surface 107 b.This allows block 100 c to be placed at a 45° angle with respect toblock 100 b, returning the orientation of block 100 c to the orientationof block 100 a. The width and length of the offset can be varied tocreate an undulation of any desired size. Moreover, any number ofundulations may be built into a wall using this technique, constrainedonly by the length of the wall and the dimensions of the block.

Oblong spaces in overlapping courses of blocks laid at a 45-degree anglemay overlay one another as was shown for straight walls above. Verticalreinforcing elements may then be inserted through adjacent oblong spacesin the courses with 45-degree corners to join these courses to oneanother.

In still another embodiment of the invention the front of a block can berounded by removing material from corners 111 a and/or 111 b of a block.The front of a rounded block can be abutted to the back of any otherblock to form any angle up to and including 45 degrees. The front of arounded block can also be abutted to the back of a block modified asshown below to form any angle up to 90 degrees.

In another embodiment of the invention a combination of blocks may beused to form a 90-degree corner FIG. 12. To form such an angle, one ofthe tail “fins” 121 is removed from block 120 a as shown in FIG. 12.This forms a block with parallel sides having differing lengths, andallows a second block 120 b to be positioned behind the modified block120 a such that one side 122 of block 120 b abuts the rear portion 125 aof block 120 a. Front angled surface 126 b abuts rear angled surface 127a as shown in the Figure.

It is to be appreciated that blocks may be positioned to provide a 45°angle or a 90° angle in a wall even when the courses of blocks do notall run in the same direction. As shown in FIG. 13, holes 18 in adjacentcourses may still line up when an undulation in a wall is provided.

Referring now to FIG. 14, construction block 140 includes sides 142,front surface 144, front angled surface 146, rear surface 145, and rearangled surface 147. Opening 149 is included in rear surface 145, andholes 148 a, 148 b, and 148 c are included in the front half of theblock. Most preferably, holes 148 a, 148 b, and 148 c are equally spacedoblong holes running through the block from the top surface through thebottom. As with prior embodiments, block 140 may have chamfered edges asshown.

In one embodiment of the present invention, blocks 10 are used toconstruct walls with a flat face substantially as previously described.Alternatively, a canted or setback wall may be constructed as shown, forexample, in FIG. 15. In that Figure, blocks 150 a, etc., within eachcourse are positioned front to back such that the front of one blockabuts the back of preceding block in the course as shown in FIG. 2.Adjacent courses 152 a, 153 a, etc., may be offset, preferably to theside of each block, by positioning successive courses such that theouter hole 158 b of an upper course is positioned over the center hole158 a of the course immediately below it. Then, reinforcing elements 155may be positioned through holes 158. Tying the course together with thevertical reinforcing elements 155 allows the canted wall to remainexceptionally strong.

It is one object of this invention to provide materials and methods forthe construction of walls for use as sound barriers or retaining wallsthat do not require the use of mortar. One feature of the blocks of thepresent invention is that they may be used to construct an integratedwall system that is effectively stabilized against vertical, horizontal,lateral and shear forces, including such forces that may be produced bywind and/or earth.

Referring now to FIG. 16, block 160 may include a channel 163 in topsurface 161. In the illustrated embodiment channel 163 extendslaterally, although channels in other directions may also oralternatively be provided. When such a channel is included a stabilizermay extend from oblong space 168 to the outside of the block. Thus, theinventive blocks may be joined to adjacent structures such as otherwalls or earth.

Walls made with the inventive blocks may be simultaneously strengthenedvertically by inserting vertical reinforcing elements through spaces 168in adjacent courses at the same time that lateral stabilizers are used.The vertical and lateral stabilizers can be used with virtually any ofthe blocks illustrated herein, wherever and whenever such verticaland/or lateral supports find advantageous use. Integrated wallstabilization is particularly important the construction of retainingwalls which may be used to contain tens of thousands or pounds of earthand therefore require extensive reinforcing.

As shown in FIG. 17, a lateral reinforcing element may be placed in alateral channel 163 and engaged to a vertical support element extendingthrough space 168 at one end, while the other end is attached to asupport some distance from the wall. It is understood that block 160having a support channel can be inserted any place in any wall whereinit is advantageous to do so. Accordingly, with the blocks of the presentinvention it is possible to secure individual blocks, and/or whole wallscomprised at least in part of such blocks, to adjacent lateralstructures such as other walls or the earth.

In one preferred embodiment the adjacent structure may be a bond beamplaced far enough behind the retaining wall that the earth wherein thebond beam is place is stable. Retaining walls are used to hold backmaterials such as soil. Any given material, including soils of variouscompositions has a natural slope, determined in part by the material'scoefficient of friction. Soil in front of the natural slope of thematerial will slide away to expose the stable slope. A bond beamconnected to soil behind the soil's stable slope and connected to thewall provides increased stability for the wall. Such a beam maybe of anylength and may be constructed of from a variety of materials includingmetal, concrete, reinforced concrete, wood, and the like. A single bondbeam or a plurality of bond beams may be placed by design in the wall toincrease the lateral stability of the wall.

Referring now to FIG. 18, a construction block 180 may be designed forincreased horizontal and or lateral stability by providing multipleholes 188. Accordingly, block 180 may include holes 188 a, 188 b, and188 c as shown in the Figure. Lateral support element 181 may extendfrom any of those holes to the outside of the block. Other holes maythen be used with vertical support members as illustrated above.

In another embodiment of the present invention illustrated in FIG. 19, ahorizontal-stabilizer 191 may be placed in a groove 193 that extendsthrough a multiplicity of blocks 190 a, 190 b, etc. Horizontalstabilizers 195 may then extend through a plurality of blocks, joiningall of them together in the horizontal direction. Horizontal stabilizers195 may also be held in place by use of any means known in the art forfixing supports to blocks such as nails, screws, rivets, glue, forexample epoxy glue, or grout.

It is to be appreciated that all blocks in a course may be joinedtogether by a horizontal stabilizer running the entire width of thewall. The horizontal stabilizer may then be fixed to the outside edgesof the wall and tensioned to increase the frictional contact between theblocks within the same course. Suitable horizontal-stabilizers mayinclude metal or composite rods, bars, straps, cables, and the like.Grooves 183 can be filled with materials like concrete, cement or groutto join the blocks together if desired.

In still another embodiment of the invention, grooves in the top face ofa block can be used to join the block to a lateral support. For example,wire mesh or the like can be set into a groove and extended into theadjacent earth or another wall. A lateral stabilizer set in a groovewithin a molded block will be more securely attached to the block thanthe same lateral stabilizer placed on the surface of a block and held inplace only by friction between adjacent and the upper and lower blocks.

Referring now to FIG. 20, a means for joining a lateral support 280 to acourse of molded blocks 284 may be made in accordance with oneembodiment the present invention. A portion of a grid 201 is set intothe earth or a concrete wall behind a molded block wall and a portion ofgrid 201 is joined to a block wall through adjacent courses in the wall.

In one preferred embodiment bars 202 on grid 201 are positioned inspaces created by chamfered edges 12 c, 14 c, 16 c, etc., on blocks 10.Grid 201 extending across the surface of a block and positioned inchamfered edges is harder to disengage from the wall than is a gridjoined to the wall by inserting the grid only between adjacent coursesof block.

Referring now to FIG. 21, a block 210 that facilitates connecting theblock to vertical and lateral supports may be made in accordance withone embodiment of the present invention. Block 210 has a space 211 inone side to better accommodate lateral and/or vertical supports. Lateralsupports for use with this invention may be in the form of an angle ironas illustrated in FIG. 22 used to engage vertical and/or horizontalsupports extending through space 211.

In another embodiment of the invention, a lateral reinforcing element isplaced in space 211 and engaged to a vertical support element extendingthrough the space and connecting the block to adjacent courses. Further,space 21 accommodating both a lateral and vertical support can be filledwith grout or concrete for added strength.

It is understood that block 210 can be inserted any place in any wallwherein it is advantageous to do so, and particularly where appropriateto facilitate connection of lateral and vertical connections between thewall and adjacent structures. Blocks 210 with a void in the side canalso be inserted in any course abutting either similar blocks or blockssuch as block 10 described above.

In one embodiment of the invention, space 211 in the side of the blockaway from the face of the wall may be filled with concrete to create acontiguous column of concrete extending up any number of courses of thewall. Blocks 210 thus may find advantageous use when block structuresare used as permanent forming structures to pour concrete walls, columnsor pilasters.

It is to be appreciated that the inventive blocks provide significantadvantages by virtue of their ability to be stabilized in any or all ofthe vertical, horizontal, and lateral directions. The vertical supportmembers discussed above are particularly useful for stabilizingsuccessive courses together, while the nose-in-tail shape of the blocks,along with the lateral and/or horizontal stabilizers, are particularlyeffective for lateral and/or horizontal stabilization. As previouslyindicated, vertical, lateral and horizontal stabilization may beachieved simultaneously when more than one stabilizing feature is used.

While the invention has been illustrated and described in detail in theforegoing description, the same is to be considered as illustrative andnot restrictive in character, it being understood that only thepreferred embodiment has been shown and described and that all changesand modifications that come within the spirit of the invention aredesired to be protected. Additional embodiments and details relating tothe present invention are disclosed in applicant's copending provisionalpatent application, including the disclosure document titled “DisclosureRelating to Materials and Methods for Constructing a Block Wall,” filedtherewith and incorporated herein by reference in its entirety.

1. A construction block for use with other construction blocks to builda wall, said construction block comprising; a) a top surface and abottom surface, said top and bottom surfaces being substantiallyparallel to one another; b) two substantially parallel side surfaces,said side surfaces being substantially perpendicular to said top andbottom surfaces; c) a front nose portion comprising a front surface thatis substantially perpendicular to the top, bottom, and side surfaces,and a pair of front angled surfaces joining the front surface to theside surfaces, wherein said front angled surfaces form a 45° angle withrespect to the front and side surfaces; e) a rear portion shaped toreceive the front end of a corresponding block when two of said blocksare placed in a front-to-end orientation, said rear portion comprising arear surface that is substantially parallel to the front nose surfaceand substantially perpendicular to the top, bottom, and side surfaces,and a pair of rear angled surfaces joining the rear surface to the sidesurfaces, wherein said rear angled surfaces form a 45° angle withrespect to the rear and side surfaces; f) a first hole extending throughthe block, wherein said hole passes vertically through the block fromthe top surface through the bottom surface, said first hole beingpositioned in the forward half of the block; and g) an indent in saidrear surface, said indent defining a second hole extending through theblock when two of said blocks are placed in a front-to-end orientation,said second hole passing vertically through the block from the topsurface through the bottom surface.
 2. A method of building a wall, saidmethod comprising: a) providing a multiplicity of construction elementsfor use with other construction elements to build a wall, each of saidmultiplicity of construction element comprising; i) a top surface and abottom surface, said top and bottom surfaces being substantiallyparallel to one another; ii) two substantially parallel side surfaces,said side surfaces being substantially perpendicular to said top andbottom surfaces; iii) a front nose portion comprising a front surfacethat is substantially perpendicular to the top, bottom, and sidesurfaces, and a pair of front angled surfaces joining the front surfaceto the side surfaces, wherein said front angled surfaces form a 45°angle with respect to the front and side surfaces; iv) a rear portionshaped to receive the front end of a corresponding block when two ofsaid blocks are placed in a front-to-end orientation, said rear portioncomprising a rear surface that is substantially parallel to the frontnose surface and substantially perpendicular to the top, bottom, andside surfaces, and a pair of rear angled surfaces joining the rearsurface to the side surfaces, wherein said rear angled surfaces form a45° angle with respect to the rear and side surfaces; and v) a firsthole extending through the block, wherein said hole passes verticallythrough the block from the top surface through the bottom surface, saidfirst hole being positioned in the forward half of the block; and vi) anindent in said rear surface, said indent defining a second holeextending through the block when two of said blocks are placed in afront-to-end orientation said second hole passing vertically through theblock from the top surface through the bottom surface; b) positioningone of said construction elements in a location desired to build a wall;c) positioning a second of said construction elements such that thefront nose portion of the second construction element fits in the rearportion of the first construction element; d) positioning additionalconstruction elements such that the nose of additional elements fitsinto the rear portion of a prior element to build a first course ofconstruction elements; e) positioning additional construction elementson top of said first course of construction elements in a like manner tobuild a second course of construction elements, wherein a hole in eachof said construction elements is vertically aligned with a hole in aconstruction element in an adjacent course; f) providing a verticalstabilizing element in a series of aligned holes to stabilize theadjacent courses of construction elements.
 3. A method of building awall, said method comprising: a) providing a multiplicity ofconstruction elements for use with other construction elements to builda wall, each of said multiplicity of construction element comprising; i)a top surface and a bottom surface, said top and bottom surfaces beingsubstantially parallel to one another; ii) two substantially parallelside surfaces, said side surfaces being substantially perpendicular tosaid top and bottom surfaces; iii) a front nose portion comprising afront surface that is substantially perpendicular to the top, bottom,and side surfaces, and a pair of front angled surfaces joining the frontsurface to the side surfaces, wherein said front angled surfaces form a45° angle with respect to the front and side surfaces; iv) a rearportion shaped to receive the front end of a corresponding block whentwo of said blocks are placed in a front-to-end orientation, said rearportion comprising a rear surface that is substantially parallel to thefront nose surface and substantially perpendicular to the top, bottom,and side surfaces, and a pair of rear angled surfaces joining the rearsurface to the side surfaces, wherein said rear angled surfaces form a45° angle with respect to the rear and side surfaces; and v) a firsthole extending through the block, wherein said hole passes verticallythrough the block from the top surface through the bottom surface, saidfirst hole being positioned in the forward half of the block; and vi) anindent in said rear surface, said indent defining a second holeextending through the block when two of said blocks are placed in afront-to-end orientation said second hole passing vertically through theblock from the top surface through the bottom surface; b) positioningone of said construction elements in a location desired to build a wall;c) positioning a second of said construction elements such that thefront nose portion of the second construction element fits in the rearportion of the first construction element; d) positioning additionalconstruction elements such that the nose of additional elements fitsinto the rear portion of a prior element to build a first course ofconstruction elements; e) positioning additional construction elementson top of said first course of construction elements in a like manner tobuild a second course of construction elements, wherein a hole in eachof said construction elements is vertically aligned with a hole in aconstruction element in an adjacent course; f) connecting a lateralstabilizing element to at least one of said construction elements tostabilize said construction element.
 4. The construction block of claim1 wherein the top and bottom surfaces of said block are substantiallyflat and free of ridges or grooves;
 5. The construction block of claim 1wherein the top and bottom surfaces of said block are free oflongitudinal grooves.
 6. The construction block of claim 4 wherein thetop and bottom surfaces of said block are free of longitudinal grooves.